A multi-layered, composite, inflatable and deflatable article of manufacture is provided. The article includes at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-permeable material, the two layers forming at least one inflatable compartment therebetween. The two layers have at least one additional layer of a porous insulating material, e.g., batting, disposed between them within the compartment. The layers are all adhesively bonded together about the periphery of the compartment and, optionally, at discrete locations within the periphery of the compartment. The porous insulating layer is otherwise unattached to either of the waterproof layers, and preferably is not otherwise attached to either. The compartment has at least one sealable opening therein through which air may be injected into or removed from the compartment, as desired, to thereby inflate or deflate the compartment to a desired volume and to thereby control its insulative value. The construct of the invention is useful, inter alia, in garments, in air mattresses, in sleeping bags, or in a combination air mattress and sleeping bag, and in various bed covers.
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4. A multi-layered composite construct having at least one inflatable and deflatable compartment therein, said construct comprising:
at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-permeable material, the two layers forming at least one compartment therebetween, the two layers having at least one additional layer of a porous insulating material disposed between said two layers, and within said compartment,
wherein said at least two layers and said additional layer are adhesively bonded together about the periphery of said compartment and, optionally, at discrete locations within the periphery of said compartment, and wherein said adhesive penetrates said porous insulating material and bonds said layers together to form a waterproof, airtight seal for said compartment extending around the periphery of said compartment,
said porous additional insulating material layer being otherwise unattached to at least one of said at least two layers, said compartment having at least one directional valved opening therein through which air may be injected into or removed from said compartment, as desired, thereby inflating or deflating said compartment to a desired volume.
1. A multi-layered composite construct having at least one inflatable and deflatable compartment therein, said construct comprising:
at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-permeable material, the two layers forming at least one compartment therebetween, the two layers having at least one additional layer of a porous insulating material disposed between said two layers, and within said compartment,
wherein said at least two layers and said additional layer are adhesively bonded together about the periphery of said compartment and, optionally, at discrete locations within the periphery of maid compartment, and wherein said adhesive penetrates said porous insulating material and bonds said layers together to form a waterproof, airtight seal for said compartment extending around the periphery of said compartment,
said porous additional insulating material layer being otherwise unattached to at least one of said at least two layers, said compartment having at least one sealable opening therein through which air may be injected into or removed from said compartment, as desired, thereby inflating or deflating said compartment to a desired volume, and
wherein said at least two layers are composite layers of
(a) a flexible, first layer of hydrophobic material having a moisture vapor transmission rate exceeding 1000 gms/m2/24 hours and an advancing water contact angle exceeding 90 degrees; and
(b) a continuous hydrophilic layer attached to the inner face of said first layer, said hydrophilic layer having a moisture vapor transmission rite exceeding 1000 gms/m2/24 hours.
2. The construct of
5. The construct of
6. The garment of
7. The garment of
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11. The construct of
12. The construct of
(a) a flexible, first layer of hydrophobic material having a moisture vapor transmission rate exceeding 1000 gms/m2/24 hours and an advancing water contact angle exceeding 90 degrees; and
(b) a continuous hydrophillic layer attached to the inner face of said first layer, said hydrophilic layer having a moisture vapor transmission rate exceeding 1000 gms/m2/24 hours.
13. The construct of
14. The construct of
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The present invention relates to insulative constructions useful in garments, sleeping bags, air mattresses and the like, wherein the insulative value of the garment or other construction is adjustable by the user. The layered construction of the invention includes an insulative layer which is adhesively fixed in place relative to all other components in the construction, thereby alleviating an existing problem associated with known insulated garments and the like, namely the migration of the insulation within garment components, resulting in undesirable hot and/or cold zones in a construction intended to be uniformly insulative.
Inflatable garments and air mattresses and the like are known. International Patent Publication WO98/10669 (19 Mar. 1998, commonly assigned), discloses an inflatable insulation module for an insulated garment which includes an inner and an outer membrane sealed together to form an inflatable cavity. The membrane is formed of a water-vapor-permeable, breathable material, allowing the escape of moisture from the wearer. The membrane is also air-impermeable to allow inflation of the module, the result being that the insulation value of the garment, for example, may be varied by the user by varying the amount of inflation introduced into the garment.
International Patent Publication WO 01/84989A1 (15 Nov. 2001) discloses a heat insulating device for an item of clothing, including a shell filled with a heat insulating material. Both this device and the aforementioned insulation module include at least one inlet/outlet for introducing a gas (air) therein in order to adjust the insulative value of the garment.
The inherent disadvantages of the known insulating constructions are substantially overcome by the insulative constructions of the present invention, which invention is described fully in the following specification and in the accompanying drawings.
A multi-layered, composite, inflatable and deflatable construct is provided. The construct includes at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-permeable material, the two layers forming at least one inflatable compartment therebetween. The two layers have at least one additional layer of a porous insulating material disposed between them within the compartment.
The at least two layers and the additional insulative layer are adhesively bonded together about the periphery of the compartment and, optionally, at discrete locations within the periphery of the compartment. The adhesive penetrates the porous insulating material and bonds the layers together to form a waterproof, airtight seal for the compartment extending around the periphery of the compartment. The porous additional insulating material layer is otherwise unattached to at least one of the waterproof layers, and preferably is otherwise unattached to either layer. The compartment has at least one sealable opening therein through which air may be injected into or removed from the compartment, as desired, to thereby inflate or deflate the compartment to a desired volume. These layers may form multiple compartments within a single construct.
Preferably, the at least two layers are of a water-vapor-permeable, i.e., “breathable”, material.
Useful constructs may include garments, such as a vest, a jacket, a pant, a glove, a coat, a hat, a sock, a boot or other suitable garment. Alternatively, the construct may be in the form of a mattress, a sleeping bag or a combination mattress and sleeping bag, or in the form of the various bed covers.
Preferably, the waterproof, air impermeable, water-vapor-permeable material is a membrane of a thermoplastic polyurethane, or a thermoplastic polyester.
The additional layer of porous insulating material is preferably a layer of a batting material, most preferably a fibrous batting material such as Primaloft® batting.
The construct may be adhesively bonded together using an adhesive from the class consisting of polyurethane, reactive polyurethane, thermoplastic polyurethane, silicone, flexible epoxy and PVC adhesives. The preferred adhesive is a thermoplastic polyurethane.
At least one reinforcing layer may be affixed to each of the at least two layers of waterproof, air impermeable, water-vapor-permeable material to impart strength and/or abrasion resistance thereto. The reinforcing layer may be a textile fabric disposed internally and/or externally of the at least two layers, or both.
The textile fabric may be of woven, knit or nonwoven fabrics, and may include nylon, polyester, polypropylene, polyaramid and cotton textile fabrics. In a preferred construction, the textile fabric is nylon.
The at least two layers may be composite layers of a flexible, first layer of hydrophobic material having a moisture vapor transmission rate exceeding 1000 gms/m2/24 hours and an advancing water contact angle exceeding 90 degrees, and a continuous hydrophilic layer attached to the inner face of the first layer, the hydrophilic layer having a moisture vapor transmission rate exceeding 1000 gms/m2/24 hours. The hydrophobic layer is preferably microporous, expanded polytetra-fluoroethylene and the hydrophilic layer may be a polyether-polyurethane.
The constructions of the invention may have multiple, additional porous insulating layers contained therein, and the sealable opening may be valved and may include, in combination, an independent air supply which may be removably affixed to the construct. The air supply may include a pump for pumping ambient air into and/or out of the compartment. In this combination, preferably, the pump is a removably attachable bellows pump and the valve is bi-directional. Alternatively, air may be injected into or extracted from the compartment orally, by blowing into or sucking out from a tube affixed to the opening.
The combination sleeping bag and air mattress of the invention is preferably one wherein the air mattress includes at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-permeable material, the two layers forming at least one compartment therebetween, the two layers having at least one additional layer of a porous insulating material disposed between the two layers, and within the compartment. The at least two layers and the additional layer are adhesively bonded together about the periphery of the compartment and, optionally, at discrete locations within the periphery of the compartment, forming a waterproof, airtight seal for the compartment extending around its periphery. The porous additional insulating material layer is otherwise unattached to at least one of the at least two layers, and preferably is otherwise unattached to either layer, and the compartment has at least one opening therein through which air may be injected into or removed from the compartment. The sleeping bag component in this combination comprises a layered composite of an outer layer of an air permeable, waterproof material, a middle layer of a porous insulating material, and an inner layer of a woven textile material, this sleeping bag component also optionally including an external shell, the air mattress component and the sleeping bag component being in registry, one to the other, and being adhesively bonded, one to the other, about the periphery of the sleeping bag component except at the access opening to the sleeping bag.
Independently and alternatively, a sleeping bag is provided including an upper panel of at least two layers of a flexible, breathable, optionally air-impermeable material, the upper layer being waterproof, the two layers forming at least one compartment therebetween, the two layers having at least one additional layer of a porous insulating material disposed between the two layers and within said compartment, the upper panel being in registry with a lower panel of at least two layers of a flexible, breathable, optionally air-impermeable material, the lower layer being waterproof with the two layers forming at least one compartment therebetween, the two layers having at least one additional layer of a porous insulating material disposed between the two layers and within said compartment, the sleeping bag also having an optional outer shell layer external to both upper and lower panels. In this construction, all layers of all panels are adhesively and sealingly bonded about the periphery of the sleeping bag except at the access opening thereof.
In the accompanying drawings:
A sleeping bag constructed according to the principles of the invention is depicted in
A multi-layered, composite, inflatable and deflatable article of manufacture is provided. The article includes at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-permeable material, the two layers forming at least one inflatable compartment therebetween. The two layers have at least one additional layer of a porous insulating material, e.g., batting, disposed between them within the compartment. The layers are all adhesively bonded together about the periphery of the compartment and, optionally, at discrete locations within the periphery of the compartment. The porous insulating layer is otherwise unattached to at least one of the waterproof layers, and preferably is otherwise unattached to either. The compartment has at least one sealable opening therein through which air may be injected into or removed from the compartment, as desired, to thereby inflate or deflate the compartment to a desired volume and to thereby control its insulative value. The con-struct of the invention is useful, inter alia, in garments, in air mattresses, in sleeping bags, or in a combination air mattress and sleeping bag, and in various bed covers.
A detailed description of the invention and its preferred embodiments is best provided with reference to the accompanying drawings wherein
Prior to sewing it together, the vest 10 is shown in pattern form in
The inflatable construct according to one aspect of the invention, whether it be a garment, an air mattress, a sleeping bag, or other construction, is formed by adhesively bonding together, to form at least one waterproof, air tight, optionally water-vapor-permeable compartment therein, at least two layers of a waterproof, air impermeable, optionally water-vapor-permeable material, and including between these two layers at least one additional layer of a porous insulating material. All of these layers are adhesively bonded together about the periphery of the compartment, and also optionally bonded together at discrete locations within the periphery of the compartment. The adhesive penetrates the interstices of the porous, insulative inner layer and affixes it in place, the result being that the insulation layer cannot move about between the two waterproof, air impermeable layers, thereby eliminating hot and cold zones caused by insulation migration within such constructions.
One embodiment of the layered construction according to the invention, and its various components, is depicted in greater detail in
Generally speaking, suitable layers which may be incorporated into constructions of the present invention may include single layer materials which are air impermeable, materials which are inherently air impermeable and moisture vapor permeable, materials which are coated or otherwise treated to render them air impermeable, materials which are coated or otherwise treated to render them air impermeable and moisture vapor permeable, or laminates of materials which incorporate an air impermeable and optionally moisture vapor permeable layer. Preferred layers are air impermeable, moisture vapor permeable fabrics which may be incorporated in the constructions of the present invention, which typically possess moisture vapor transmission rates (MVTR) in the range of greater than 2000 g/m2/24 hours, more preferably greater than 5000 g/m2/24 hours. A particularly preferred laminate for use in the present invention comprises a laminate of a microporous membrane and an air-impermeable, moisture-vapor-permeable layer, available from W. L. Gore & Associates, Inc., Elkton, Md. Another particularly preferred laminate for use in the present invention comprises a laminate containing a breathable polyurethane layer that is air-impermeable and moisture-vapor-permeable such as those available from Narcote, LLC, Piney Flats, Tenn. These are discussed further in the examples which follow.
The preferred air-impermeable, moisture-vapor-permeable materials include, but are not limited to, polyurethane and composites of polyurethane and PTFE. Preferred polyurethane layers, alone or used as a composite with other materials, may have a thickness of 0.005 inches or less, preferably 0.003 inches or less. Most preferred polyurethanes have thicknesses of 0.002 or less to 0.0015 or less. This air-impermeable, moisture-vapor-permeable material is laminated or coated on at least one side of a reinforcing textile layer to form the breathable fabric layer. Preferred breathable fabric layers include PTFE/polyurethane composites laminated to knit or nonwoven fibrous sheets, polyurethanes laminated to knits or nonwovens, and particularly preferred are expanded PTFE/polyurethane composites.
The various layers are all arranged as shown schematically in
After the adhesive 18 is applied in the desired pattern as beading between the layers of composite as shown in
The present invention is also useful in sleep systems wherein variable insulation is often desired. As an air mattress, this invention can be used to provide an insulation layer between two airtight layers so that, when inflated, the mattress provides both cushioning and thermal insulation. Upon deflation, air can be withdrawn from the mattress to create a very small, stowable, package that is ideal for carrying and storage.
A schematic perspective view of an air mattress constructed according to the principles of the invention, partly in cross-section, is depicted in FIG. 9. The air mattress is formed with a plurality of transversely extending inflatable compartments sealingly separated, one from the other, along the plurality of seams 47, except that openings 110 permit the passage of air from compartment to compartment. The outer shell layer 42, and its adjacent layers, are all sealed along the transverse seams 47 and at the peripheral seams 47 shown in the figure. The longitudinal cross-section through this air mattress reveals the insulative layer 46, fixed and anchored within the air mattress, and having inflatable air compartments 50, 50 adjacent thereto. An opening 108, through which air may be introduced or expelled, as desired, is shown schematically in the figure.
In a further alternate configuration of a construction according to another aspect of the invention, shown in
One (of many possible) attachable, removable, portable and convenient valved air pumps for use in inflating and/or deflating the inflatable compartments in the constructs of the invention is shown in FIG. 12. Therein, a bellows pump is depicted having a top 72, bellows 70, base 61, adjustable ring diverter 62, having port 64, the ring diverter 62 being circumferentially affixable to the base 61 and slidably rotatable with respect thereto. Resilient spring 74 forces the bellows 70 to return to “open” upon compression of the bellows. Detent 63, which snaps over the ledge in the inner ring 65 within the base 61 provides attachment means for affixing the ring 62 to the base 61. One-way valves 66 complete the construction of this rudimentary, valved, portable air pump. Such an air pump is intended to be illustrated as removably attachable to the garment illustrated in
Flow through the inlet/outlet port 64 of the pump of
Referring to
To forcibly expel air from the inflated compartment attached to the port 64, the ring 62 is rotated diametrically with respect to the pump base, as depicted in FIG. 15. Therein, on compression of the bellows, air is forcibly pumped out of the inflatable compartment, and into the atmosphere, all as indicated by the bold arrows in
The specific examples which follow are presented as illustrative of inflatable/deflatable constructions prepared according to the principles underlying the disclosed invention. However, these examples should not be construed as limiting in any way the scope of the invention disclosed herein, which scope is defined exclusively by the appended claims and equivalents thereof.
An insulated deflatable/inflatable garment in the form of a vest was fabricated by first cutting two fabric panels and a polyester batt layer all having substantially the geometry shown in FIG. 3. One fabric panel which was to be the outer panel comprised a laminate of a 90 g/m2 polyester, circular knit, shell layer, a 30-micron thick microporous expanded PTFE membrane having a 15-micron thick, air-impermeable, moisture-vapor-permeable polyurethane layer laminated on the membrane side opposite the shell layer, and a 30 g/m2 inner polyester warp knit layer. The second fabric panel, which was to be the inner panel, comprised a laminate of a 30-g/m2 polyester, warp knit shell layer, a 30-micron thick, microporous expanded PTFE membrane having a 15-micron thick, air-impermeable, moisture-vapor-permeable polyurethane layer on the membrane side opposite the shell layer, and a 30 g/m2 inner polyester warp knit layer. Such fabric panels are available from W. L. Gore & Associates, Inc., Newark, Del., under the trademark Gore-Tex® waterproof, breathable laminates. The outer fabric panel was laid flat with the warp knit facing upwardly. Next the polyester batt layer was laid on top of the fabric panel so that both layers had the same orientation. Such polyester batting is available from Albany International, Inc., Albany, N.Y., under the trademark Primaloft®. The preferred batt insulation was 3.0-oz/square yard batting, designated Primaloft Sport®. Then a reactive polyurethane adhesive bead was applied onto the batt layer in a pattern substantially corresponding to the pattern in
To form an inflation/deflation construct, a hole was cut in one of the fabric panels and a valve and fitting attached. In this example, the fitting was bonded to the fabric panel using a polyurethane adhesive.
The insulation level of this variably inflatable/deflatable insulated vest construct was adjustable by either extracting or injecting air into the sealed compartment therein through the attached valve and fitting.
An insulated deflatable/inflatable module of the present invention was constructed in the same manner as in Example 1 except different fabric panels were employed. In this example, both fabric panels comprised a 2-layer laminate of a polyester knit layer having an affixed waterproof, breathable monolithic polyurethane layer. Such waterproof, breathable polyurethane laminates are available from Narcote, LLC, Piney Flats, Tenn., as Part Number 2400-1710-1X-Black Interlock. Each fabric panel was oriented so that the monolithic polyurethane film was exposed toward the polyester batting and the textile was facing outwardly. This lay-up before and after sealing is depicted schematically in
To form an inflation/deflation module, a hole was cut in one of the fabric panels and a valve or fitting attached. In this example, the fitting was bonded to the fabric panel using a polyurethane adhesive.
The insulation level of this variable inflatable/deflatable insulated module was then adjustable by either extracting or injecting air into the sealed compartment therein through the attached valve or fitting.
An insulated deflatable/inflatable module of the present invention was constructed in the same manner as in Example 2 except different fabric panels were employed. In this example, both fabric panels comprised a 3-layer laminate of polyester knit outer and inner layers and a waterproof, breathable, monolithic polyurethane center layer. Such waterproof, breathable polyurethane laminates are available from Narcote, LLC, Piney Flats, Tenn., as Part Number 2400-1710-404 Black Fabric. Each pre-cut fabric panel was laid-up so that the knit that was desired to face inwardly was oriented toward the polyester batting, thus leaving the outer textile facing outwardly. This lay-up, after being adhesively sealed, is analogous to that depicted in FIG. 8.
To form an inflation/deflation module, a hole was cut in one of the fabric panels and a valve fitting attached. In this example, the fitting was bonded to the fabric panel using a polyurethane adhesive.
The insulation level of this variable inflatable/deflatable insulated module was then adjustable by either extracting or injecting air into the sealed compartment therein through the attached valve or fitting.
An insulated air mattress was constructed by first cutting two rectangular fabric panels having substantially the geometry shown in FIG. 9. Each fabric panel comprised a laminate of a polyester knit outer shell layer 42, a microporous expanded PTFE membrane 44 having an air-impermeable, moisture-vapor-permeable polyurethane layer on the membrane side opposite the shell layer, and an inner polyester knit layer 45. An extruded polyurethane adhesive bead 48, approximately 0.125″ diameter, was laid in parallel lines and across the end as depicted in FIG. 9. Insulative batting 46 was then cut to the same pattern and laid on top of the first fabric panel and adhesive. The second fabric panel was then laid on top of the insulative batting. These three stacked layers were placed in a platen press which had a heated top platen and contained a raised shim so that pressure was applied predominately to the area of the adhesive beads. A clamping pressure of about 10 psi was generated on the raised area that encompassed the adhesive beading. The press was closed until the adhesive bead reached its melting temperature. The thermoplastic polyurethane adhesive used in this example had a melt temperature of 180° C. and a low melt viscosity. This process took about 1 minute to reach the desired temperature, the press was then opened, and the finished, insulated air mattress withdrawn. Fittings were glued into the opening 108 in one of the panels to allow air to be added or withdrawn using an external, portable removably attachable bellows pump, similar to that depicted in FIG. 12.
A waterproof sleeping bag was constructed by first cutting two rectangular fabric panels in dimensions of 36×72 inches. Each fabric panel comprised a laminate of a nylon woven outer shell layer, a microporous expanded PTFE membrane and an inner polyester knit layer. An extruded polyurethane adhesive bead approximately 0.2 inches in diameter was laid along both long and one short edge of the rectangle on one of the panels. Insulative batting was then cut to the same pattern and laid on top of the adhesive beads. Two layers of a liner fabric consisting of 60 g/m2 woven nylon were placed on the batting, followed by a second layer of batting and the second nylon/expanded PTFE polyester laminate fabric panel. These stacked layers were then placed in a platen press. The press had a heated top platen and contained a raised shim so that pressure was applied predominately in the area of the adhesive beads. A clamping pressure of about 10 psi was generated in the raised area proximate the adhesive bead. The press was closed until the adhesive bead reached its melting temperature. The thermoplastic polyurethane adhesive used in this example was the low melt viscosity adhesive as above, which melted at approximately 180° C. This construction process took approximately 3 minutes to reach the desired temperature. The press was then opened and the finished sleeping bag was withdrawn. This process created a waterproof seam, as illustrated in
While the invention has been disclosed herein in connection with certain embodiments and detailed descriptions, it will be clear to one skilled in the art that modifications or variations of such details can be made without deviating from the gist of this invention, and such modifications or variations are considered to be within the scope of the claims hereinbelow.
Lack, Craig D., Farnworth, Brian
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Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
Aug 26 2002 | LACK, CRAIG D | W L GORE ENTERPRISE HOLDINGS, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 013244 | /0193 | |
Aug 26 2002 | FARNWORTH, BRIAN | W L GORE ENTERPRISE HOLDINGS, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 013244 | /0193 | |
Aug 29 2002 | Core Enterprise Holdings, Inc. | (assignment on the face of the patent) | / | |||
Jan 30 2012 | Gore Enterprise Holdings, Inc | W L GORE & ASSOCIATES, INC | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 027906 | /0508 |
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